Protective ball cap

ABSTRACT

A protective insert for a ball cap and a cap incorporating the same. The insert includes a rigid shell and a complementary impact-absorbent liner that covers and protects only the forehead and portions of the sides of the user&#39;s head. Bottom edges of the shell, liner, and cap are generally aligned along the same horizontal plane. Alternatively, the shell and liner terminate a distance inwardly from the bottom edge of the cap. An adjustable band is secured to the ends of the shell and the band and shell encircle the circumference of the user&#39;s head. One or more engagement members may secure the insert to the cap. The material of the liner is thicker in a front central region and thinner toward the side regions of the insert. The liner material extends beyond the top edge of the shell so that the shell does not directly contact the user&#39;s head.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.14/710,672, filed May 13, 2015, which is a Continuation-in-Part of U.S.patent application Ser. No. 29/513,002 filed Dec. 24, 2014, now U.S.Pat. No. D765,918 which is a Continuation-in-Part of U.S. patentapplication Ser. No. 13/942,179, filed Jul. 15, 2013, the entirespecifications of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION Technical Field

This invention is directed to hats. More specifically, this direction isdirected to hats or caps. Most particularly, this direction is directedto a cap which includes a protective insert. Specifically, the cap hasthe appearance of a traditional ball cap and the insert includes a rigidshell and an impact absorbent liner which only cover and protect theuser's forehead and the sides of their head, and where each of the shelland liner have bottom edges that are generally aligned with a bottomedge of the cap and are therefore substantially invisible to onlookers.

Background Information

One of the issues that tee-ball, baseball and softball users mayexperience is that a struck ball, such as one hit in a line drive, or abat that is accidentally released may strike a user in the head, causingan impact injury such as a concussion, a fracture or catastrophicimpacts that may cause intracranial bleeding leading to death. This isparticularly problematic when it comes to ball games played by younger,less experienced and less skilled users who may not be able to direct astruck ball in a particular direction with any certainty. This type ofinjury may also occur if a ball or bat strikes a spectator by accident.

While many users, such as batters wear protective helmets, a largepercentage of users do not or will not wear such protective gear.Additionally, it is highly unlikely that any spectator will be wearingsome type of protective helmet when they show up to watch a game.Traditionally both users and spectators prefer to wear a traditionalbaseball cap.

There have been a number of attempts made in the past to provideprotection on the outside of a ball cap, but the fact is if theprotective components cover the “team” logo or if the hat looks bulkyand somehow not traditional, children, in particular, will not wear sucha cap.

There have also been numerous attempts at providing protectivecomponents in interiors of hats but many of the resultant products havebeen bulky and unsightly and therefore less desirable for people towear.

Examples of previously known devices include that disclosed in U.S. Pat.No. 3,268,911 (Cox). Cox discloses a conventional hat having adome-shaped protective shell made of hard plastic received therein. Theshell is configured complementary to the inner surface of the hat andfits snugly within the space defined by the hat's inner surface. Agenerally X-shaped harness assembly made of a flexible plastic isdisposed within a space defined by the shell. The harness is secured toa bottom region of the shell by cooperating buttons and holes disposedon the shell and harness. When the harness is engaged in the shell, acrown-region of the harness rests on the top of the user's head and thecrown-region is disposed a distance downwardly away from the protectiveshell. An annular sweatband is secured to the ends of the harness and isdisposed aligned with an annular bottom region of the shell and insidethe bottom edge of the hat. Resilient pads are glued at intervals to theinner surface of the shell. In particular, the pads are provided at thecrown region of the shell and at spaced temple positions around thecircumference of the shell. The spacing between the pads allows forventilation of the hat. The harness engages the user's head and theprotective pads and the shell are thereby disposed a short distance fromthe user's head. The user's head is not in contact with the pads.

Heine et al (U.S. Pat. No. 4,675,919) discloses a headband for mountingof optical instruments. The headband includes a first region whichpasses around the circumference of the head and a second region whichextends from the first region and passes over the user's head.Cushioning pads are detachably engaged around portions of the first andsecond regions and contact the user's head. There is no disclosure inthe patent that the headband provides any type of protection for thehead, just that the headband is useful for mounting instruments thereon.

Graham (U.S. Pat. No. 4,982,451) discloses a resilient adjustable linerfor a hat, particularly a soft, yarn hat. The liner is fabricated from aresilient and flexible plastic that is U-shaped when viewed from thetop. The liner includes a central region that is configured to bedisposed adjacent the back of a user's head and two side regions thatare configured to extend downwardly over the user's cheeks. A slot inthe band is positionable over the user's forehead. The liner is ofuniform thickness along its entire length. Plastic fasteners engage theliner to the hat. Apertures are provided in the liner in a locationwhich will fall adjacent the user's ears. The hat is pulled over theliner and covers the entire liner.

Benston et al (U.S. Pat. No. 5,025,504) discloses a disposable liner fora hat or cap which is an elongate, trapezoidally-shaped member that isadhered to a portion of the inner surface of the hat or cap. The linerincludes a central region for positioning adjacent the user's foreheadand two tapering side regions extending outwardly from the centralregion. The side regions are configured so as to extend across theregion of the user's head across the upper regions of their temples. Theliner is designed as a sweatband and includes a liquid absorbingmaterial disposed between an interior and exterior wall. The liquidabsorbing material is disposed in discrete pockets which are separatedfrom each other by regions which are free of liquid absorbing material.

Leach (U.S. Pat. No. 5,226,180) discloses a golfing helmet that includesan outer hat or cap that is conventional. An impact absorbing Styrofoamliner is placed in the interior of the cap. The hemispherical linerincludes elongate openings for ventilation. The liner is glued into thecap. Similarly, Anderson (U.S. Pat. No. 5,289,591) discloses a plasticinsert for a golf cap. The insert is generally hemispherical except fora semi-circular cut-out in the back of the insert which allows foradjustment of the cap. The insert is provided with apertures forventilation.

U.S. Pat. No. 5,437,064 (Hamaguchi) discloses a protective cap thatincludes a first padding assembly comprising a circular band that isconfigured to encircle a user's head and be seated inside the bottomedge of a hat. The first padding assembly also includes twosemi-circular bands which are connected to the circular band and areconfigured to pass from front-to-back and from side-to-side across thecrown of the user's head. The first padding assembly is detachablysecured to the inside of the hat by way of hook and loop fasteners. Theprotective cap further includes a second padding assembly which isreceived within a space defined by the first padding assembly. Thesecond padding assembly includes an outer fabric layer and an innerresilient foam layer. The second padding assembly is configured tocontact the user's head.

Moore, III et al (U.S. Pat. No. 6,154,889) discloses a protective helmetmade from a resilient shell that has a plurality of radial slits thereinwhich enable the shell's width to be adjusted. The shell is fabricatedfrom a hard material and a liner fabricated from an energy absorbingmaterial is disposed inside the shell. The shell is a hemispherical domeand includes regions which extend downwardly to cover a user's temples.

Blair (U.S. Pat. No. 7,096,512) discloses a protective sports hat insertwhich includes a solid outer shell, an inner high-density foam liner,and may include a washable cloth layer. The outer shell is domed andhemispherical in shape and the inner liner is complementary in shape tothe outer shell. The inner liner may be fabricated in a variety ofconfigurations that may be “folded into” the space defined by the outershell. Preferably, inner liner is spaced from outer shell to providesome additional shock absorption when the hat receives an impact blow.The inner liner tapers at its bottom edge.

Motroni (US 2012/0131731) discloses an insert fora ball cap. The insertis configured to extend along the front wall of the cap and therebyprotect the forehead of the user. The insert is made from plastic andmay be placed adjacent the front wall or be glued or otherwise securedin place.

SUMMARY

While all of the above protective devices work adequately for thepurposes for which they were intended, there remains a need in the artfor an improved protective cap which has the outward appearance of atraditional cap but which aids in protecting the most vulnerable areasof the user's head.

A protective insert for a ball cap and a cap incorporating the same. Theinsert includes a rigid shell and a complementary impact-absorbent linerthat covers and protects only the forehead and portions of the sides ofthe user's head. Bottom edges of the shell, liner, and cap are generallyaligned along the same horizontal plane. Alternatively, the shell andliner terminate a distance inwardly from the bottom edge of the cap. Anadjustable band is secured to the ends of the shell and the band andshell encircle the circumference of the user's head. One or moreengagement members may secure the insert to the cap. The material of theliner is thicker in a front central region and thinner toward the sideregions of the insert. The liner material extends beyond the top edge ofthe shell so that the shell does not directly contact the user's head.

In one aspect, the invention may provide a protective insert for a capto be worn on a user's head, said insert comprising an outer shelladapted to be received within a space defined by an inner surface of anouter wall of the cap; said shell being adapted to cover only the user'sforehead and sides of their head; and an inner liner complementary inshape to the outer shell; wherein the liner is positioned adjacent aninner surface of the shell and is adapted to be disposed adjacent theuser's head.

In another aspect, the invention may provide a cap assembly forprotecting a user's head; said assembly comprising a cap including asubstantially hemispherical outer wall having an inner surface and abottom edge; a space defined by the inner surface of the outer wall; anda protective insert receivable within the space; wherein said insertcomprises an outer shell adapted to cover only the user's forehead andsides of their head; an inner liner complementary in shape to aninterior surface of the outer shell; wherein the liner is adapted to bedisposed adjacent the user's forehead and the sides of the user's head;wherein each of the shell and liner has a bottom edge and wherein thebottom edges of the liner and the shell do not extend beyond the bottomedge of the cap.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A sample embodiment of the invention, illustrative of the best mode inwhich Applicant contemplates applying the principles, is set forth inthe following description, is shown in the drawings and is particularlyand distinctly pointed out and set forth in the appended claims.

FIG. 1 shows a perspective view of a ball cap in accordance with anaspect of the present invention with the cap being shown worn on auser's head and showing a portion of a first embodiment of a protectiveinsert extending outwardly from the cap and positioned adjacent theuser's temple;

FIG. 2 is a perspective view of the first embodiment of the protectiveinsert for the ball cap shown worn on the user's head but with the capremoved from the user's head for clarity;

FIG. 3 is a perspective view of the insert removed from the user's head;

FIG. 4 is an exploded perspective view of the insert of FIG. 3;

FIG. 5 is a top view of the insert;

FIG. 6 is a left side view of the insert;

FIG. 7 is a front plan view of the insert;

FIG. 8 is a bottom perspective view of the insert;

FIG. 9 is an enlarged perspective view of the highlighted region of FIG.3;

FIG. 10 is a cross-sectional side view of the ball cap with insertengaged therewith shown worn on a user's head;

FIG. 11 is a cross-sectional front view of the ball cap and insert wornon a user's head with the cross-section being taken along line 11-11 ofFIG. 6;

FIG. 12 shows a perspective view of a ball cap in accordance with anaspect of the present invention with the cap being shown worn on auser's head; where the ball cap includes a second embodiment of aprotective insert but that insert is substantially not visible to anobserver;

FIG. 13 is a perspective view of the second embodiment of the protectiveinsert for the ball cap shown worn on the user's head but with the capremoved from the user's head for clarity;

FIG. 14 is a perspective view of the insert removed from the user'shead;

FIG. 15 is an exploded view of the second embodiment of the insert;

FIG. 16 is a second perspective view thereof;

FIG. 17 is a right side view of the protective liner for a ball cap; theleft side view not being illustrated herein but being a mirror imagethereof;

FIG. 18 is a bottom view of the protective liner for a ball cap;

FIG. 19 is a top view thereof;

FIG. 20 is a front view thereof; and

FIG. 21 is a rear view thereof.

Similar numbers refer to similar parts throughout the drawings.

DETAILED DESCRIPTION

Referring to FIGS. 1-11, there is shown a ball cap assembly 10 whichincludes a cap 11 and a first embodiment of a protective insert 12.FIGS. 12-20 show a ball cap assembly 110 which includes a cap 11 and asecond embodiment of a protective insert 112. Cap assemblies 10 and 110are configured to have the appearance of a traditional baseball cap thatis worn by players and spectators of the game. Cap assemblies 10, 110may, in fact, include a traditional baseball cap 11 that is worn on auser's head 14. It will be understood that while a traditional baseballcap 11 is illustrated in the attached figures, other types of hats andcaps worn by golfers and other athletes can be provided with aprotective insert 12 or 112 in accordance with aspects of the presentinvention. In those instances, the insert will be configured to becomplementary to the specific shape and features of the hat or cap inquestion.

Cap 11 comprises a substantially dome-shaped wall 16 which has anexterior surface 16 a and an inner surface 16 b (FIG. 10). Wall 16 has abottom edge 16 c which substantially circumscribes the user's head 14when cap 11 is worn thereon. Wall 16 includes a frontal region and apeak 18 extends outwardly and forwardly away from the bottom edge 16 c.Cap 11 has an interior diameter “D” (FIG. 10) which closely approximatesthe diameter of the user's head 14. Cap 11 defines an interior chamber22 (FIG. 10) into which both insert 12 and the user's head 14 arereceived.

FIG. 2 illustrates insert 12 alone engaged about the user's head 14. Inthis figure, cap 11 has been removed for clarity. FIG. 3 illustratesinsert 12 standing on its own and not engaged about a user's head. Itwill be noted that the insert 12 is not the traditional domedhemispherical shape that covers the entire head of the user. Instead,insert 12 is configured to protect the user's forehead, temples, andareas immediately above the ears. The crown and back of the user's headdo not have any portion of the insert 12 covering them, except for theregions covered by securing straps, as will be later described herein.This configuration of insert 12 fits into a traditional cap 11 andprotects the most vulnerable portions of the head but has the additionalbenefit of allowing air to circulate freely around the crown and back ofthe head.

FIG. 4 shows an exploded view of insert 12 and in this view it can beseen that insert 12 comprises a first component and a second component.The first component is an outer shell 24 and the second component is apad 26. Pad 26 is configured to be complementary to at least a frontportion of outer shell 24. Pad 26 may be adhesively engaged with shell24 or shell 24 may be placed in a mold and the foam pad 26 isinjection-molded around shell 24.

Referring to FIGS. 4 and 5, outer shell 24 has an exterior surface 24 a,an inner surface 24 b, a top edge 24 c and a bottom edge 24 d. Pad 26has an exterior surface 26 a, an inner surface 26 b, a top edge 26 c,and a bottom edge 26 d. As is evident from the figures, pad 26 isconfigured to be engaged with outer shell 24 such that inner surface 24b of shell 24 is disposed adjacent exterior surface 26 a of pad 26.Outer shell 24 may be fabricated from a relatively thick, strong, andrigid material such as polycarbonate plastic. Pad 26 may be fabricatedfrom a high density foam that will tend to readily absorb impact forces.Pad 26 may be provided to decelerate impact from a ball hit and isfabricated from a visco-elastic material or foam having a heavy densityof around 0.38 g/cm3.

Shell 24 may be approximately 0.1″ thick and pad 26 varies in thicknessfrom about 0.1″ thick to about 0.32″ thick, with the thickness beingmeasured between the respective interior and exterior surfaces of shell24 and pad 26. Pad 26 may be a molded foam pad of complex geometry andhas verifying thickness in that frontal region 50 is thicker thanterminal regions 54. Pad 26 tapers between frontal region 50 andterminal regions 54 so that there is a smooth transition to band 34. Thetapering pad thickness also helps ensure that the overall circumferenceof cap 11 is kept as small as possible.

Outer shell 24 includes a frontal region 28 sized and positioned tocover and protect the user's forehead 14 a. Outer shell 24 furtherincludes at least one but preferably a pair of temporal regions 30 (FIG.7). Temporal region 30 is a projection which extends downwardly beyondor below bottom edge 24 d of outer shell and is positioned and shaped toat least partially cover and protect one of the user's temples. Outershell 24 may include two opposed temporal regions 30 which are opposedprojections that extend outwardly and downwardly below bottom edge 24 dof outer shell and each of these projections at least partially coversand projects one of the user's temples.

Each temporal region 30 may be generally V-shaped and when pad 26 isengaged with shell 24, at least a portion of each V-shaped temporalregion 30 will extend for a distance downwardly below bottom edge 16 cof cap 11. (It will be understood that the projections that comprisetemporal region 30 may be shaped differently. For instance, they may begenerally semi-circular in shape.) A terminal region 32 extendsrearwardly from each temporal region 30 and is configured to cover andprotect a portion of the sides of the user's head immediately above theear 14 b (FIG. 11).

A band 34 extends between the opposed terminal regions 32 of shell 24and is threaded through apertures 36 defined in each terminal region 32.Band 34 is adjustable to fit the user's head and thereby retain shell 24and pad 26 adjacent thereto. Band 34 is semi-circular in shape and isconfigured to form a horizontally oriented semi-circular arch. Band 34in conjunction with outer shell 24 fits circumferentially around theuser's head 14 in a horizontal orientation.

In accordance with an aspect of cap assembly 10, at least one engagementmember is provided on one or both of outer shell 24 and wall 16 tosecure the insert 12 to cap 11. The engagement member includes but isnot limited to one or more pin members 38, a detent 60, or hook and loopfasteners (not shown). The engagement member(s) extend outwardly andforwardly from frontal region 28 of shell 24 and toward inner surface 16b of outer wall 16 of cap 11. Alternatively, the engagement member(s)may be provided on cap 11 and extend inwardly toward shell 24.

A first engagement member is provided in the form of one or more pinmembers 38 provided on exterior surface 24 a of shell and which extendtoward and engage inner surface 16 b of wall 16 adjacent frontal region28. Pin members 38 interlockingly engage cap 11 and shell 24 together.Pin members 38 may be disposed in one or more rows or columns in an areaof shell 24 that will directly overlay the user's forehead. Pin members38 may be spaced at intervals a distance apart from each other and theymay be of uniform diameter along their lengths. Pin members 38frictionally engage the inner surface of outer wall 16 and thus aid inpreventing cap 11 from lifting upwardly off insert 12 when the windblows.

In accordance with yet another aspect of cap assembly 10, a first strap40 and a second strap 42 are provided on insert 12. First strap 40extends between opposed flanges 44 provided on terminal regions 32 ofshell 24. First strap 40 is threaded through an aperture 46 (FIG. 4) ineach flange. Although not illustrated herein, it will be understood thathook and loop fastener strips are provided on an exterior surface offirst strap 40 proximate each free end 40 a, 40 b (FIG. 7) thereof andon an inner surface of each free end 40 a, 40 b. The hook and loopfastener strips enable the overall length of first strap 40 betweenflanges 44 to be adjusted. First strap 40 is semi-circular in shape andis configured to pass from side-to-side of outer shell 24 and pass overthe crown of the user's head. First strap 40 thus forms a verticallyoriented semi-circular arch relative to outer shell 24. First strap 40does not engage band 34 which passes around the back of the user's head.

As best seen in FIG. 9, second strap 42 is threaded through an aperture48 defined in frontal region 28 and extends rearwardly therefrom. Secondstrap 42 may be fixedly secured to first strap 40 approximately midwaybetween flanges 44.

Second strap 42 may be stitched to first strap 40 or be otherwisefixedly secured thereto. Second strap 42 may also be fixedly secured tofrontal region 28 by threaded free end 42 a thereof through aperture 48and stitching free end 42 a to a portion of second strap 42. Thus,second strap 42 may be of a fixed length as measured between frontalregion 28 and first strap 40. Although not illustrated herein, it willbe understood that hook and loop fastener strips may, alternatively, beprovided between free end 42 a of second strap 42 and the inner surfaceof second strap 42 so that the overall length of second strap 42 betweenfrontal region 28 and first strap 40 is able to be adjusted so as tomore closely fit the user's head 14. Second strap is configured to becurved and pass from the front of the user's head to the crown of theirhead. Second strap 42 does not extend to the back of the user's head.

Thus, first strap 40 extends from proximate the user's left ear 14 b toproximate the user's right ear 14 b. The second strap 42 extends fromproximate the top of the user's forehead to proximate the crown of theuser's head. At least two of these three bands/straps 34, 40, and 42 maybe adjustable so that the user can change the overall dimensions ofinsert 12 to most closely and snugly fit their head. Each of band/straps34, 40, and 42 may be fabricated from a flexible fabric material, suchas a cotton fabric, which makes them relatively easy to adjust. Thishelps ensure that the protective outer shell 24 and pad 26 are locatedin the optimum positions on the user's head to protect them from impact.Apart from apertures 36, 46, 48 outer shell 24 is substantiallycontinuous and uninterrupted along its length and width.

Protective pad 26 is complementary in shape to the rigid outer shell 24.Only the three bands/straps 34, 40, and 42 on the outer shell 24 arefree of any of the padding material. Thus as shown in FIG. 4, pad 26includes a frontal region 50, opposed temporal regions 52, and opposedterminal regions 54. Temporal regions 52 are also generally V-shapedmembers that extend below bottom edge 16 c of wall 16. As best seen inFIG. 1, temporal regions 52 may be each slightly bigger than temporalregions 30 of shell 24. Pad 26 is slightly larger in height than shell24 so that a lip of foam padding extends above and below the upper andlower edges of shell 24. The foam lip extends around substantially theentire outer edge of shell 24 so there are no unprotected edges of thestiff outer shell 24 that could injure or cut the user if impacted by abat or ball. Pad 26 is comprised of an impact-absorbing material andthis material is substantially continuous along the entire inner surface24 b of outer shell 24. Thus, there are substantially no regions oninner surface 24 b that are free of the impact-absorbing material.

As best seen in FIGS. 6 and 7, substantially the entire bottom edge 24 dof shell 24 lies generally along a plane “P”. Similarly, substantiallythe entire bottom edge 26 c of liner 26 is disposed generally along aplane “P1”. Two sections of bottom edge 24 d and bottom edge 26 d arenot aligned along planes “P” and “P1”. These two sections are located onprojections 30 which extend outwardly for a distance below planes “P”and “P1”. The projections 30 comprise temporal regions on cap assembly10 which are provided to extend over and cover the temples of the userwearing cap assembly 10. It should be noted that bottom edge 16 c of cap11 is disposed either generally aligned with plane “P1” or a distancedownwardly below plane “P1”. Consequently, when the cap assembly 10 isworn, as illustrated in FIG. 1, substantially little to none of thebottom edge 24 d of outer shell 24 or the bottom edge 26 d of liner isvisible. The only portions of the insert that are visible are the twotemporal regions or projections 30 and possibly a small section of theterminal regions 54 of the insert.

The upper edge 26 c of pad 26 is configured to have a pair of opposeddepressions 56 (FIG. 4) formed therein to accommodate flanges 44. Upperedge 26 c further defines a recess 58 in the central region of shell 24to accommodate part of the second strap 42 which is threaded throughaperture 46 in frontal region 28 of shell 24. Pad 26 also includes asecond engagement member in the form of the substantially horizontaldetent 60 which extends outwardly from a bottom edge of frontal region50 of liner 26. Detent 60 extends for a distance beyond frontal region28 of shell 24 and toward the inner surface of outer wall 16 of cap 11.As best seen in FIG. 10, detent 60 extends for a short distance belowpeak 18 of cap 11. The weight of peak 18 on detent 60 aids in keepinginsert 12 engaged on the user's head, particularly on the front of theuser's head. Detent 60 also tends to prevent cap 11 from slidingdownwardly on the user's head 14 and thus ensures that frontal regions28, 50 are properly situated on the user's head to protect the forehead,temples and regions above the ears against impact.

Cap assembly 10 is substantially free of any protective componentsdisposed on the exterior surface 16 a of wall 16. In other words, theexterior surface of cap assembly 10 has the appearance of a traditionalbaseball cap that is free of any protective elements. Only small partsof temporal regions 30, 52 are visible as these regions extenddownwardly below bottom edge 16 c of cap 11 to protect the vulnerabletemples of the user.

Cap assembly 10 is specifically designed for different head sizes usingaccurate human head CAD models in increments of two head sizes. Thissizing is due at least partially to the fairly rigid and unforgivingouter shell 24 which is very specific to head size in order to keep theoverall thickness of insert 12 thin enough so that cap 11 selected forthe assembly 10 is only required to be a slightly larger hat size thannormally would be worn by the user. The overall cap size for a user willtend to be around two or three larger hat sizes than would be the caseif a regular baseball cap was to be worn. The user adjusts one or moreof the bands/straps 34, 40, and 42 to ensure a snug fit for the insert12 on the user's head 14.

The insert 12 provides significant protection from balls moving toward auser's forehead and/or sides of their head 14. This is due to the factthat most users, particularly ball players, are positioned to directlyface the ball with either their foreheads or the sides of their headback to slightly rear of their ears. Furthermore, most users willinstinctively turn their head to avoid a direct face hit and therebybring their temples into a position where they could be struck by aflying ball. A ball hit in baseball is different than in football wherethe head is the projectile and cushioning in the football helmet hassome distance to decelerate the brain. Cap assembly 10 is provided toprotect against a ball hit where the impact from a ball hit mustdissipate over a wider area where there is some compression of theunderlying protective padding 26.

Referring now to FIGS. 12-20, there is illustrated a cap assembly 110which includes a cap 11 and a second embodiment of a protective insert112 (FIG. 13). Ball cap 11 is substantially identical to the cap shownin FIGS. 1-11 and therefore will not be described in any additionaldetail herein.

FIG. 13 illustrates insert 112 shown engaged on the user's head 14 whileFIG. 14 illustrates insert 112 on its own and not engaged about a user'shead 14. As with insert 12, insert 112 is not a traditionaldomed-hemispherical shape that would cover the entire head of the user.Instead, insert 112 is shaped, sized, and located so as to protect onlythe user's forehead and an upper portion of the user's temples and areasimmediately above the ears. The crown and back of the user's head do nothave any portion of the insert 112 other than a flexible band 134covering them, as will be later described herein. This configuration ofinsert 112 fits into a traditional ball cap 11 and protects the mostvulnerable portions of the head but has the additional benefit ofallowing air to circulate freely around the crown and back of the head.Additionally, this second embodiment of the insert 112 is substantiallyinvisible because a bottom edge of the insert 112 is either aligned witha bottom edge 16 c of cap 11 or terminates a distance inwardly andupwardly from bottom edge 16 c. In other words, the bottom edge ofinsert 112 does not extend below bottom edge 16 c of cap 11. In otherinstances, however, the bottom edge of the insert 112 may project for avery short distance below bottom edge 16 c of cap 11.

Insert 112 is comprised of first and second components. The firstcomponent is an outer shell 124 that is received in a space defined byan interior surface of the ball cap 11. The second component is a lineror protective liner 126 that is received in a space defined by an innersurface of the outer shell 124, as will be described below. Liner 126 isconfigured to be complementary to outer shell 124. Liner 126 may beadhesively engaged to the inner surface of shell 124 or shell 124 may beplaced in a mold and the foam liner 126 is then injection-molded aroundshell 124. Both shell 124 and liner 126 are generally U-shaped whenviewed from above and include a central or frontal region which coverssubstantially all of the exterior surface of the user's forehead 14 a,particularly of the user's upper forehead. Additionally, both shell 124and liner 126 include side regions which are designed to cover upperportions of the side regions of the user' head including portions of thetemples and areas above the ears.

Referring to FIGS. 14-16, outer shell 124 has an exterior surface 124 a,an inner surface 124 b (FIG. 15), a top edge 124 c and a bottom edge 124d. Liner 126 has an exterior surface 126 a (FIG. 15), an inner surface126 b, a top edge 126 c, and a bottom edge 126 d. As is evident from thefigures, liner 126 is configured to be engaged with outer shell 124 suchthat inner surface 124 b of shell 124 is adjacent exterior surface 126 aof liner 126. Outer shell 124 may be fabricated from a relatively thick,strong, and rigid material such as a polycarbonate plastic. Liner 126may be fabricated from a material that will tend to readily absorbimpact forces. Liner 126 is provided to decelerate impact from a ballhit and may be fabricated from a visco-elastic material or a foam havinga heavy density, such as a density of around 0.38 g/cm3.

Referring to FIGS. 15-21, outer shell 124 includes a central frontalregion 128 sized and positioned to cover and protect most of the user'sforehead 14 a. Outer shell 124 also includes a pair of opposed side orterminal regions 132 which extend rearwardly and outwardly from eitherside of the central frontal region 128. Terminal regions 132 may bepositioned and shaped to cover and protect an upper portion of the sidesof the user's head above the temple and above the ear 14 b (FIG. 11).Unlike outer shell 24, outer shell 124 does not include any temporalregions, similar to temporal regions 30, which will extend outwardly anddownwardly below bottom edge 124 d of outer shell 124.

Outer shell 124 has a top edge 124 c and a bottom edge 124 d. A firstportion of the top edge 124 c extends along a top end of the frontregional 128, a second portion of the top edge 124 c extends along a topend of a first one of the temporal or side regions 30, and a thirdportion of the top edge 124 c extends along a top edge of a second oneof the temporal or side regions 30. Frontal region 128 of outer shell124 is of a height “H” (FIG. 17) measured between the first portion ofthe top edge 124 c and the bottom edge 124 d thereof. Terminal regions132 are each of a height “H1” measured between the associated second orthird portion of the top edge 124 c and bottom edge 124 d. The height“H1” is smaller than the height “H”. The entire bottom edge 124 d ofouter shell 124, i.e., the bottom edge of frontal region 128 and thebottom edges of the first and second terminal regions 132 may be locatedin generally the same plane “P2”, as is illustrated in FIG. 17. This isnot the case with the first portion of the top edge 124 c of the frontalregion 128 and the second and third portions of the top edge 124 c ofthe terminal regions 132. The first portion of the top edge 124 clocated on frontal region 128 is located a distance outwardly beyond thesecond and third portions of top edge 124 c located on terminal regions132. An angled portion 131 (FIG. 17) of the top edge 124 c extendsbetween the first portion of the top edge 124 c of frontal region 128and teach of the second and third portions of the top edge 124 c ofterminal regions 132.

A band 134 extends between the free ends of the two terminal regions 132of shell 124. Band 134 is threaded through apertures 136 defined in eachterminal region 132. Band 134 and outer shell 124 together form a closedloop that is adapted to circumscribe or encircle the circumference ofthe user's head.

Referring to FIG. 17 it can be seen that front region 128 of shell 124is curved. (Liner 126 is similarly curved). This curvature results inthe circumference of insert 112 being greatest proximate bottom edge 124d of shell 124 and smallest proximate top edge 124 c. The difference inthe circumference between top and bottom edges 124 c, 124 d is evidentin FIGS. 18 and 19 where it can be seen that the distance between theinterior surface of band 134 (which would be located adjacent the backof the user's head) and the interior surface of liner 126 (which wouldbe located adjacent the user's forehead) decreases from the bottom (FIG.18) to the top (FIG. 19) of insert 112. The circumference of insert 112progressively decreases in size between the bottom edge and the top edgeof insert 112. The curvature of insert 112 and the decreasingcircumference thereof assists in keeping the insert 112 seated on theuser's head 14 because the curvature and circumferential decreasemirrors the shape of the human head.

Band 134 may be fabricated from an elastic or resilient material and maybe selectively adjustable in length so as to enable insert 112 to snuglyfit the user's head. Band 134 may be semi-circular in shape and isconfigured to form a horizontally oriented semi-circular arch. Band 134in conjunction with outer shell 124 fits circumferentially around theuser's head 14 in a horizontal orientation. Band 134 may include anysuitable type of closure mechanism thereon, such as hook and loopfasteners or, alternatively, band 134 may be threaded through apertures136 and be simply stitched back upon itself.

It should be noted that there are no other bands or straps on insert112. Particularly, there are no straps such as the straps 40 and 42 ofcap assembly 12 which pass over the top of the user's head. Theanatomical curvature of the user's upper forehead area 14 a issufficient to keep the outer shell 124 of insert 112 on the foreheadwhen the length of the band 134 is correctly adjusted.

Insert 12 is illustrated as including some suitable type of anengagement member provided on one or both of the outer shell 24 andinterior surface of the cap 11 in order to secure insert 12 to cap 11.In that instance, the engagement member is disclosed as being one ormore pin members 38, a detent 60, or hook and loop fasteners (notshown). Similar engagement members may be provided on insert 112 but nosuch engagement members are illustrated in FIGS. 12-20. While a detent60 may be provided on insert 112, such a component is preferably omittedtherefrom. Instead, the padding of liner 126 is trimmed so that bottomedge 126 d of liner 126 will be flush with bottom edge 124 d of shell124 so as to limit the visibility of liner 126. Preferably, the onlycomponents keeping outer shell 124 engaged with cap 11 is a plurality ofpin members (not shown in the figures) similar to pin members 38. Itwill be understood that any other type of engagement member may beutilized on outer shell 124 instead of the pin members. Inserts 12 and112 are each of a type that is detachable and independent from cap 11but it will be understood that either protective insert 12, 112 may beadhesively or otherwise permanently secured to cap 11.

Liner 126 is substantially complementary in shape to the rigid outershell 124 of insert 112. Liner 126 is comprised of an impact absorbingpadding material and only band 134 is free of any of padding material.As shown in FIG. 15, liner 126 includes a frontal or central region 150and a pair of terminal or side regions 154. Terminal regions 154 extendoutwardly from opposite sides of frontal region 150 and in oppositedirections to each other. The upper edge 126 c of liner 126 includesangled sections 127 (FIG. 15) which are shaped and sized to be generallyaligned with angled sections 131 on outer shell 124.

As indicated previously, liner 126 may be comprised of animpact-absorbing material and this material is substantially continuousalong the entire inner surface 124 b of outer shell 124. Thus, there aresubstantially no regions on inner surface 124 b that are free of theimpact-absorbing material. It will be understood that instead of liner126 being continuous, there may be breaks or holes at intervals in theliner 126. Liner 126 may be a molded foam pad of complex geometry andmay be thicker in frontal region 150 (FIG. 16) thereof than in theterminal regions 154 thereof. Liner 126 may taper in both height andthickness from frontal region 150 outwardly to terminal regions 154.This tapering will ensure that there is a smooth transition from shell124 to band 134. The tapering pad thickness also helps ensure that theoverall circumference of cap 11 is kept as small as possible. Shell 124may be approximately 0.1″ thick and liner 126 may vary in thickness fromabout 0.1″ thick to about 0.32″ thick, with the thickness being measuredbetween the respective interior and exterior surfaces of shell 124 andliner 126.

In insert 112, liner 126 may extend slightly beyond top edge 124 c ofshell 124 so that a lip of foam padding extends above top edge 124 c.The foam lip may extend around substantially the entire top edge 124 cof shell 124 so there are no unprotected edges thereon that may injureor cut the user if impacted by a bat or ball. Liner 126 may be trimmedalong its bottom edge 126 d so that bottom edges 124 d of shell 124 andbottom edge 126 d of liner are substantially horizontally aligned witheach other. As best seen in FIG. 17, substantially the entire bottomedge 124 d of shell 124 and the entire bottom edge 126 d of insert 126may be oriented along a plane “P2”. It should further be noted thatbottom edge 16 c (FIG. 12) of cap 11 may be substantially aligned withbottom edges 124 d and 126 d f insert 112 along plane “P2”. This has theeffect of making the protective insert 112 substantially invisible andgives the appearance that the user is wearing a regular ball cap and nota protective ball cap.

It will be understood that instead of the bottom edge 16 c of the capbeing aligned with bottom edges 124 d, 126 d of insert 112, the bottomedges 124 d, 126 d may project for a short distance downwardly belowbottom edge 16 c. Even in this instance, when the cap assembly 10 isworn, as illustrated in FIG. 12, substantially little to none of bottomedge 124 d of outer shell 124 or bottom edge 126 d of liner 126 may bevisible.

Cap assembly 110, like cap assembly 10, is substantially free of anyprotective components disposed on the exterior surface 16 a of wall 16.In other words, the exterior surface of cap assembly 10 has theappearance of a traditional baseball cap that is free of any protectiveelements. Only small sections of outer shell 124 and protective liner126 may be visible—if they extend partially below bottom edge 16 c ofcap 11.

Cap assembly 110, like cap assembly 10, may be specifically designed fordifferent head sizes using accurate human head CAD models in incrementsof two head sizes. This sizing is due, at least partially, to the fairlyrigid and unforgiving material of the outer shell 124 which isfabricated to be very specific to a particular head size. This is donein order to keep the overall thickness of insert 112 thin enough so thatcap 11 selected to be part of assembly 110 is only required to be aslightly larger hat size than normally would be worn by the user. Theoverall cap size for a user will tend to be around two or three largerhat sizes than would be the case if a regular baseball cap was to beworn. The user may adjust band 134 to ensure a snug fit for the insert112 on the user's head 14.

Cap assembly 110 is used in substantially the same manner as capassembly 10 and may provide protection against ball hits on the frontand/or sides of the user' head 14, as has been previously described.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued.

Moreover, the description and illustration of the preferred embodimentof the invention are an example and the invention is not limited to theexact details shown or described.

1. A protective insert for a cap to be worn on a user's head, saidinsert comprising: an outer shell that is rigid, said outer shell beingadapted to cover only a user's forehead and the sides of the user'shead, wherein the outer shell is configured so that it will not extendover any portion of the top of the user's head; wherein a frontal regionof the outer shell has a top edge and a bottom edge that are adapted tobe located adjacent the user's forehead; an impact absorbent inner linerhaving an exterior surface abutting an inner surface of the outer shell;said inner liner further having an interior surface adapted to conformto the user's forehead and to the sides of the user's head; wherein theinner liner directly contacts the user's forehead and the sides of theuser's head from a top edge of the inner liner through to a bottom edgeof the inner liner; and a flexible band that extends between a first endand a second end of the outer shell; and wherein the band and shell areadapted to encircle a user's head and to be secured therearound.
 2. Theinsert as defined in claim 1, wherein each of the outer shell and linerare U-shaped when viewed from the top.
 3. The insert as defined in claim1, wherein the band is adjustable in length; and adjustment of thelength of the band changes a circumferential diameter of the insert. 4.The insert as defined in claim 1, wherein the inner liner comprises alayer of padding comprised of a high density foam.
 5. The insert asdefined in claim 4, wherein the padding of the inner liner extendsupwardly to at least a top edge of the outer shell.
 6. The insert asdefined in claim 4, wherein the padding is continuous along the entireinner surface of the outer shell and the padding is free of apertures.7. The insert as defined in claim 4 wherein the padding is eitheradhesively secured to the outer shell or is injection molded around theouter shell.
 8. The insert as defined in claim 1, wherein the outershell is fabricated from polycarbonate and the inner liner is fabricatedfrom a visco-elastic material.
 9. The insert as defined in claim 1,further comprising at least one engagement member provided on anexterior surface of the outer shell, said engagement member beingadapted to engage an inner surface of an outer wall of the cap.
 10. Theinsert as defined in claim 9, wherein the at least one engagement memberis one or more pin members that project outwardly from the exteriorsurface of the outer shell.
 11. The insert as defined in claim 1,wherein an upper portion of the insert is of a smaller diameter than alower portion of the insert.
 12. The insert as defined in claim 1,wherein the entire inner liner from a top edge thereof to a bottom edgethereof is in direct abutting contact with the user's head and there areno regions of the inner liner that are spaced a distance away from theuser's head.
 13. A cap assembly for protecting a user's head; saidassembly comprising: a cap including an outer wall that is hemisphericaland has a bottom edge; wherein said outer wall includes a front region,a back region; a top region and opposed side regions that bound anddefine an interior space into which a user's head is received when thecap is worn; wherein the front region is adapted to be located in frontof the user's forehead when the cap is worn on the user's head; whereinthe back region is adapted to be located behind a back of the user'shead; the side regions are adapted to be located next to the sides ofthe user's head; and the top region is adapted to be located above a topof the user's head; and a protective insert that is independent of thecap and is selectively engageable around the user's head prior topositioning the cap thereover; wherein the protective insert is adaptedto be in direct abutting contact with the user's head; wherein theuser's head and the engaged protective insert are receivable within thespace defined by the cap; and wherein the protective insert comprises:an outer shell that is rigid and U-shaped, said outer shell beingpositionable proximate only the front region and the side regions of theouter wall of the cap, wherein the outer shell is configured so that itwill not extend over any portion of the top of the user's head; whereinat least a portion of the outer shell is spaced a distance away from aninterior surface of the cap's front wall; and wherein the outer shelldoes not extend upwardly to a position adjacent the top region of thecap's outer wall; an impact absorbent inner liner complementary in shapeto an inner surface of the outer shell said inner liner being adapted tobe placed in abutting contact with the user's head; and a band extendingfrom a first end of the outer shell to a second end of the outer shell;said band being adapted to contact the back of the user's head when theprotective insert is engaged on the user's head; wherein the bandindependently secures the protective insert around the user's head. 14.The cap assembly as defined in claim 13, wherein the inner liner has aninterior surface and an exterior surface; and the exterior surface islocated adjacent the inner surface of the outer shell; and wherein theinterior surface of the inner liner is adapted to rest on the user'sforehead and sides of the user's head when the protective insert isindependently secured around the user's head.
 15. The cap assembly asdefined in claim 13, wherein the outer shell has an upper end and alower end and both of the upper and lower end are located adjacent thefront region of the cap's outer wall.
 16. The cap assembly as defined inclaim 13, wherein the inner liner has an upper end and a lower end andboth of the upper end and the lower end of the inner liner are locatedadjacent the front region of the cap's outer wall.
 17. The cap assemblyas defined in claim 16, wherein the lower end of the inner liner islocated flush with or inwardly with respect to the bottom edge of thecap.
 18. The cap assembly as defined in claim 13, wherein the cap'souter wall is made from a fabric, the outer shell of the protectiveinsert is fabricated from a rigid material and the inner liner of theinsert is fabricated from an impact absorbing material.
 19. A method ofprotecting a user's head from impact comprising steps of: providing aprotective insert and a cap, wherein the protective insert isindependent of the cap and is positionable on a user's headindependently of the cap and prior to placement of the cap on the user'shead; wherein the protective insert comprises a rigid outer shell havingan impact absorbing inner liner provided on an inner surface of theouter shell, and wherein the protective insert is configured so that itwill not extend over any portion of the top of the user's head; placingthe inner liner against the user's forehead and sides of the user's headand so that an upper end of the inner liner and a lower end of the innerliner are both located on the user's forehead and wherein the innerliner and the outer shell do not extend over any portion of the top ofthe user's head; placing a band secured to the outer shell around a backof the user's head; adjusting a length of the band to hold the innerliner tightly against the user's forehead; conforming the inner liner toa shape of the user's forehead so that the inner liner from a top edgethereof to a bottom edge thereof and the inner liner between the topedge and the bottom edge are in direct contact with the user's forehead;placing a cap over the user's head; and placing the cap over theprotective insert that has been previously engaged around the user'shead.
 20. The method as defined in claim 19, further comprising:contacting the insert only with a bottom edge region of the cap.
 21. Themethod as defined in claim 19, wherein the placing of the cap over theuser's head further includes covering a portion of the user's head thatis not located under the protective insert; and wherein the portion ofthe user's head includes a top region of the user's head that issituated a distance above and rearwardly of the user's forehead.
 22. Themethod as defined in claim 19, further comprising: frictionally engaginga lower exterior region of a frontal region of the outer shell with aninterior surface of a bottom edge region of the cap.
 23. The insert asdefined in claim 1, further comprising a first projection provided onone or both of the outer shell and the liner, wherein the firstprojection extends downwardly for a distance below the bottom edge ofthe shell; and wherein the first projection is positioned on the one orboth of the outer shell and the liner so as to be adapted to cover oneof the user's temples.
 24. The insert as defined in claim 23, whereinthe one or both of the outer shell and the liner further comprises asecond projection that is opposed to the first projection; and thesecond projection extends downwardly for a distance below the bottomedge of the shell; and wherein the second projection is positioned onthe one or both of the outer shell and the liner so as to be adapted tocover the other of the user's temples.
 25. The cap assembly as definedin claim 13, further comprising a first projection provided on one orboth of the outer shell and the liner, wherein the first projectionextends downwardly for a distance below the bottom edge of the cap; andwherein the first projection is positioned on the one or both of theouter shell and the liner so as to be adapted to cover one of the user'stemples.
 26. The cap assembly as defined in claim 25, wherein the one orboth of the outer shell and the liner further comprises a secondprojection that is opposed to the first projection; and the secondprojection extends downwardly for a distance below the bottom edge ofthe cap; and wherein the second projection is positioned on the one orboth of the outer shell and the liner so as to be adapted to cover theother of the user's temples.
 27. The method as defined in claim 19,further comprising: extending a first projection downwardly from one orboth of the outer shell and beyond a bottom edge of the cap; andpositioning the first projection in a location where the firstprojection will protect one of the user's temples.
 28. The method asdefined in claim 27, further comprising: extending a second projectiondownwardly from one or both of the outer shell and beyond the bottomedge of the cap in a position opposed to the first projection; andpositioning the second projection in a location where the secondprojection will protect the other of the user's temples.